How Can Industrial Companies Reduce Downtime

In an industrial setup, downtime happens when the day-to-day processes come to a halt. This could be planned downtime, a scheduled halt for an upgrade, or an unplanned downtime caused by electrical or mechanical failure. No matter the reason, the results can be far-reaching and even devastating.

Let’s establish one thing: Downtime is inevitable. That said, there are numerous ways to reduce its frequency or time period. Here are three ways industrial companies can reduce the amount of downtime they have to deal with:

1. Adopt Appropriate Maintenance Strategies

Robust maintenance strategies form the foundation of an efficiently-running company. There are three types of maintenance strategies you can adopt to reduce downtime:

Predictive maintenance – it involves utilising real-time data from sensors, performance monitors, and analytics to predict when a component or system is likely to fail. This allows companies to perform necessary upgrades and repairs before an issue could occur.

Preventive maintenance – this involves scheduled tasks, such as lubrication or replacement of parts, to keep equipment in optimal condition. This can extend the lifespan of machinery, saving you from heavy costs.

Corrective maintenance – it is a reactive approach. A corrective maintenance strategy prepares a company in the event of an unexpected failure. Knowing what to do beforehand can minimise disruptions and resolve issues promptly.

Remember, when you pre-empt a failure, you can prepare for it or even prevent it.

2. Keep Upgrading Electrical Infrastructure

The electrical infrastructure of an industrial building directly determines its functioning. Outdated or overloaded systems cause downtime and lead to missed opportunities.

Start by conducting a thorough assessment of the existing system’s capacity. Have an expert identify potential hazards like arc flash risks and pinpoint areas needing upgrades. Next, determine the facility’s specific power requirements and growth plans, if any. Develop a detailed plan focusing on materials that require upgrades.

Pay special attention to the power distribution system of the industrial facility. For instance, you can replace old fuses with Miniature Circuit Breakers (MCBs). They offer faster and safer fault protection. A miniature circuit breaker automatically trips in the event of overloads or short circuits, isolating only the affected circuit without disrupting the entire operation. This will help minimise downtime and offer long-term protection of your heavy-duty machinery.

3. Train Your Staff

Employees are the backbone of an industrial facility. Unfortunately, human error is a leading cause of unplanned outages in industrial settings. This is why staff training is a crucial part of any downtime reduction strategy.

Well-trained personnel can quickly spot signs of wear and tear and equipment damage. They can also be trained to follow proper safety procedures, such as isolating the equipment so the damage doesn’t interrupt other operations. This will prevent small issues from turning into disasters.

Staff training should cover both preventive and emergency response training. This can include teaching how to reset a circuit breaker safely, operating backup systems, and reporting faults immediately. Look into advanced courses and workshops so their knowledge stays current, especially when the industrial setup needs to incorporate a new technological system.